Method of producing cloth boards



Noy. 22, 1927.

H. B. SMITH METHOD OF PRODUCING CLOTH BOARDS Filed Oct. 5, 1 922 2heets-Sheet l A a Q m INVENTOR A TTORNE ys H. B. SMITH METHOD OFPRODUCING CLOTH BOARDS Nov. 22, 1927.

Filed Oct. 5, 1922 2 Sheets-Sheet 2 i A TTORNE Ys Patented Nov. 22,1927.

UNITED, STATES PATENT OFFICE.

BRIDGMAN SMITH, 0F BROOKLYN, NEW YORK, AS8168 OR TO LIGHTBHIP CLOTHBOARD CORPORATION, OF BROOKLYN, NEW YORK, A CORPORATION 01' new YORK.

METHOD 0] PRODUCING CLOTH BOARDS.

My invention relates to methods of producing cloth boards of especiallystrong and economical laminated constructlon, by what .I call continuousoperations, thatns to say, by advancing certain of the materials 1 ncontinuous strip form and performmgvarious operations upon the materialsduring such advance. l/Vhile the advancing movement of the materials maybe uninterrupted,

0 it is not necessarily so, since in some cases intermittent movementmay be provided for without departing from the general plan of advancingthe materials in a predetermined course, or through a definite series ofwork positions until completed individual articles, such as clothboards,are finally produced. While some of the materials are initially advancedin continuous or strip form, it is not essential that all of thematerials shall be so advanced, and, in fact, animportant feature of theinvention is the provision of means for advancing and properlyassociating with the continuous or strip materials, successive blanks orseparate sheets or pieces of material, as more fully explainedhereafter.

Cloth boards used as cores or winders for certain classes of fabrics,for instance, woolen fabrics, are subjected to especially heavy strains,and these strains are especially severe in the transverse direction ofthe board. These severe transverse strains are caused by shrinkage ofthe goods which is frequently 'sufiicient to crack or break transverselyboards as at present constructed, and especially expensive and heavyboard structures are therefore provided for this class of fabrics inorder to prevent bending, cracking, or breaking of the boards. Animportant object of my invention is to provide improved methods ofproducing laminated cloth boards of fibrous sheet material, usuallycardboard or pulp board, in which the fibre arrangement of certain ofthe layers or laminations is generally in a longitudinal direction ofthe board, while the fibre arrangement of other laminations is in thetransverse direction of the board to give the desired lateral stifinessto resist the compression strains of fabric such as woolens, and to alsoprovide, when necessary or desirable, a smooth covering for thelaminated core or body of the board.

The characteristics and advantages of the invention .are furthersufliciently explained in connection with .the detailed description ofthe accompanying drawings which show certain representative forms of thecloth boards produced, and also show in a diagrammatic way certainproduction methods, and in these method diagrams certaininstrumentalities for performing some of the operations are indicated ina diagrammatic way although it is not attempted to show completemechanisms, nor is there any limitation as to the mechanisms orinstrumentalities which may be employed to'perform the differentoperations, and in fact, the process may be carried out in its variousforms entirely by hand or with the aid of elementary hand implements.

After consideringthese various exemplifications of the invention personsskilled in the art will understand that many modifications may be made,and I contem late the employment of any methods w ich are properlywithin the scope of the appended claims. I

In the drawings:

Figure 1 is a diagrammatic view showing one performance of the process.I

Figure 1 is a continuation of Fig. 1.

Figure 2 is a top plan of the underlying portion of Fig. 1.

Figure 2 is a top plan of the underlying portion of Fig. 1*.-

Figure 3 is a perspective view of the materials as they are associatedand formed by the process of Figures 1 and 1.

Figure 4 is a perspective View of a completed cloth board produced bythe method of Figures 1 to 3.

Figure 5 is a perspective view illustrating materials in process ofassociation and formation to produce another form of the cloth board.

Figure 6 is a transverse section sufiiciently explaining the structureof a cloth board produced by the method of Fig. 5.

Referring first to the process as explained in Figures 1 to 3 inclusive,continuous strips 1, 2 and 3 of suitable fibrous sheet material, such aspulp board or cardboard of suitablev grade and thickness, are advancedtoward different points of assembly contact, and usually the strips aremost conveniently suppliediin the form of rolls 4, 5 and 6 respectively, and continuously advanced from the rolls, the word continuouslyas here used being in the broader aspect of the invention considered tocover either the continuous form of the strips during various assemblyoperations, or to the enerally continuous advance movement, which,however, may be checked or interrupted at different olnts, depending onthe nature of the operatlons or apparatus employed. In a more restrictedsense, however, and in accordance with certain preferred forms of themethod, the advance movement of the continuous strip materials may beuninterrupted.

The fibres in sheet material of this class are generally arranged moreor less in the direction of the length of the strip as it comes from theroll, this fibre arrangement in the continuous lon itudinal strips beingsufiiciently indicated y longitudinal shading in Fig. 3. Such materialhas very substantial resistance to longitudinal bending, but owing tothe fibre arrangement has less resistance to transverse bending, that isto say, strains applied which tend to bend or crush the materialwidthwise; and to provide the desired additional widthwise or transversestrength in the completed board, it is desired to supply one or morelayers of similar material in which the fibre arrangement is transversethe board or at a right angle to the fibre arrangement of the strips 1,2 and 3. For this purpose fibrous sheet material with fibres mainlytransversely arranged is supplied in the present em odimcnt of theinvention between strips 1 and 2, and between strips 2 and 3, and while,in the broader aspect of the invention, there is no limitation as to themanner in which the material. in its transverse fibre arrangement may besupplied, in the presentperformance of the process this sheet materialwith the transverse fibres is desirably supplied in the form of separatepieces of convenient length which are fed consecutively between thecontinuous strips so as to form in practical effect a continuous layeror lamination.

In accordance with this .embodiment. of the process a plurality ofpieces 7 of the sheet material cut to a suitable length are arranged ina stack holder 8. These pieces are desirably produced by cutting themtransversely from a continuous roll of the sheet material of suitablewidth, and they are then arranged in the stack so that the fibres of thematerial run transversely, as is v sufiiciently indicated by transverse.surface shading in Fig. 3. The width of these pieces, as also clearlyindicated in Fig. 3, is the same as the width of the continuous strips1, 2 and 3. The stack holder 8 is positioned so that the pieces 7 arefed successively from the stack at suitable intervals, any suitablebottom feed mechanism 9 being provided for this purpose in the presentinstance.

A plurality of similar sheets or pieces 10 is also similarly arranged ina stack holder for stack 11. As the sheets 7 or 10 are separated andadvanced from their stack they may be definitely fed forward between therespective continuous strips by any suitable feed mechanism, such asco-operative rolls 12 and 13, and the action of these feed rolls isregulated so that the forward edge of one sheet is brought in contactwith the rear.

edge of the preceding sheet as the sheets pass between the continuousstrips, and desirably a buckle as at 14 is produced in each piece as itis brought in contact with the preceding piece to insure proper endcontact of the pieces in the continuous assembly.

It is of course desirable to secure the materials tightly together, andfor this purpose a suitable adhesive, such as glue, is supplied in anysuitable way. Evidently glue may be supplied to surfaces of thecontinuous strips, or to both surfaces of the filler pieces such as 7,or to one surface of one of the strips and to one surface of each of thefiller pieces. Referring now particularly to the method of producing thepartial assembly consistin of the strips 1 and 2 with their intermediatefiller pieces 7, glue'is sup plied to the under surface of strip 1 byany suitable glue mechanism including a glue roll 15, and glue issupplied to the under surfaces of the pieces 7 by the feed roll 13previously mentioned, which in the present instance also acts as a glueroll and is supplied with glue in any suitable way, for instance, by theglue trough and distributing roll 16. The parts of the preliminary orpartial assembly 17, consisting of strips 1 and 2 and consecutive pieces7, are then passed between pressing rolls 18 and firmly pressedtogether.

At the same time in the present performance of the process anotherpreliminary or subordinate assembly 19 is produced consisting of thecontinuous strip 3 and the consecutive pieces 10, and in this instancethe under surfaces of the pieces 10 are glued by roll 13 which acts as a.glue roll in the same manner as described in connection with theroduction of the other subordinate assemly; and the materials composingthe subordinate' assembly 19 are pressed together by rolls 20. The twosubordinate assemblies are then brought together and pressed betweenrolls 21 with adhesive r-eviously supplied, for instance, by a g ue-roll22 arranged to supply glue to the under surface of strip 2.

To provide a suitable smooth finish for thebody or core structure, astrip of cover material 24, which may be sheet material of any suitablecharacter, usually paper or cardboard thinner than the filler materials,and when desired of a better quality, s advanced from a roll 25 and overany suitable guide rolls, such as 26 and 27, and associated with theadvancing assembly 23. Prior to contact glue is supplied to unite the'cover with the core assembly, and desirably 1n the present instancethis glue is applied to a surface of the strip 24, that is, the surfacewhich is to engage with the filler assembly 23, by a glue roll 28. Thecomplete assembly, consisting of the com osite filler and the coversheet, is then pass through any s u1table cover folding and formingmechanism, sufiiciently indicated in the present instance by a foldingchannel 30 having side walls suitably curved to gradually bend marginsof the cover sheet 24 upward and then over upon the upper surface of thecore assembly, that is, the upper surface of strip 1, with the covermaterial smoothly overlying the edges of the'core assembly, until thecore is entirely covered with the cover sheet as indicated at the rightin Fig. 3. The longitudinal edges 31 may be arranged to more or lessclosely abut or meet, or alap joint may be provided as shown at 32, Fig.5. The

edge formation of the' cover may be im-' proved or fixed by edgepressing rolls 33, and the entire assembly may then be pressed betweenupper and lower pressing rolls 34. The assembly is then cut transverselyat regular intervals by any suitable cutting mech anism, sufficientlyindicated at 35, producing individual cloth boards B, Figures 1' and 4.These boards, produced by the described performance of the process.include a composite core or filler consisting of one or more, usually aplurality, of longitudinal strips of material with the fibre thereoflongitudinally arranged, and one or more, usually a plurality, ofinterposed layers of sheet material, usually in the form of separatepieces with abutting ends, and with the fibre thereln arrangedtransversely so that great resistance is provided against widthwisecrushing strains as well as against longitudinal bend ing. The core iscompletely and smoothly encased in a sheet of suitable cover ma terial24 having smooth edges 36, the corners of which as at 37 may be more orless rounded when desired by the suitable formation or action of theedge pressing rolls 33.

Figures 5 and 6 show another form of cloth board in which certain of thefiller layers may consist of sheets of fiat fibrous material with thefibres running lengthwise of the board. for instance, sheets 1, 2 and 3as in the previous example, with alternating layers of substantiallycellular or corrugated fibrous sheet material 40 and 41, thecorrugations of which in the present instance are arranged transverselyof the board to impart the greatest possible lateral stiffness. Inproducing this type of board according to a method sufficientlyillustrated in Fig. 5, the corrugated sheets are most desirabl suppliedin the form which is known as ouble faced corrugated board in which thecorrugated materal is covered on both sides with a sheet of fibrousmaterial, such as suitable paper or cardboard 42 and 43, these facingsheets being adhcsively secured to the crests of the corrugations.Double faced corrugated board of this sort may be cut into piecessimilar to the pieces 7 or 10 in the previous example of the invention,and may then be handled in a similar way in producing a continuous coreassembly as shown in F 1g. 5, adhesive being of course supplied betweenthe outer sides of the facing sheets 42 and 43, and the adjacentsurfaces of the continuous strips 1, 2 and 3, and the assembly beingsuitably pressed and then enclosed in a cover sheet 45, substantially asin the previous example, the cover material in this case, however, beingwide enough to provide a lap joint 32.

This form of construction, with the corrugated filler sheets, provides aboard which is in some cases lighter than the other form while providingsulficient strength and stiffness, and particularly sufficient strengthto resist transverse crushing or bending strains for certain classes ofgoods.

Certain parts or all of the filler materials may be impregnated orotherwise treated when desired with suitable strengthening or stiffeningmaterials. For instance, the corrugated sheet material 40, which in manycases may be of relatively low grade and cheap material such asstrawboard', may be impregnated or otherwise treated with a solution 'ofsodium silicate, or a suitable glue size, and similarly when necessaryor desirable the other filler material, such as the sheets 1, 2, 3, orthe filler pieces 7 or 10, may be similarly treated to provideadditional strength or stiffness.

' I claim:

1. A method of producing composite structures of the class described,consisting of multiple layers of sheet material such as card board,comprising advancing a continuous web of such material, advancing andassociating with the web such material to cover successive areas of theweb and form a. core structure, and folding and securing laterallyprojecting portions of the web at the opposite side of the corestructure.

2. A method of producing composite structures of the class described,consi ting of multiple layers of sheet material such as, cardboard,comprising advancing a continuous web of such material, and advancingand associating with the web successive pieces of such material inedgewise contact to form a continuous core structure, and folding andsecuring laterally projecting portions of the web at the opposite side.0 the core structure.

3. A method of producing composite structures consisting of multiplelayers of sheet-material such as cardboard, comprising advancing acontinuous web of such material, advancing and applying to the websuccessive pieces ofsuch material to form a. core structure, and foldingand securing side portions of the continuous'web to enclose the corestructure and form a cover therefor.

4. A method of producing composite structures of the class described,consisting of multiple layers of sheet material, such as cardboard,comprising advancing a continuous web of such material, and advancingand ast'ociating with the web successive pieces of such material inedgewise contact to form a. continuous core structure, folding andsecuring laterally projecting portions of the web at the opposite sideof the core structure, and.

6. A method of producing cloth boards and similar articles comprisingadvancing a continuous strip of sheet fibrous material, advancingsuccessive pieces of sheet fibrous material of substantially the samewidth as the strip and securing said pieces adhesively on a surface ofthe strip in endwise contact with each other, enclosing the associatedmaterials in a cover sheet, and severing the assembly so producedtransversely at intervals to produce individual cloth boards.

7. A method of producing cloth boards and similar articles comprisingadvancing two strips of sheet fibrous material, advancing successivepieces of sheet fibrous material and adhesively securing them in endwisecontact between the two str ps, enclosing the core assembly so producedin an envelope of sheet fibrous material, and severing the completeassembly transversely at intervals to produce individual cloth boards. a

8. A method of producing cloth boards and similar articles comprisingadvancing two continuous strips of sheet fibrous material in which thefibres are arranged mainly longitudinally, advancing successive piecesof sheet fibrous material in which the fibres are arranged mainlytransversely, adhesiveand similar articles comprising advancing aplurality of continuous strips of sheet fibrous material in which thefibres are arranged mainly longitudinally, advancing successive piecesof sheet fibrous material in which the fibres are arranged mainlytransversely and adhesively securing said pieces in endwise contactbetween each two continuous strips, thus producing a core assembly,advancing a continuous strip of sheet fibrous cover material, foldingthe cover strip about the core assembly and adhesivcly securing it toform a continuous envelope, and severing the complete assemblytransversely to produce individual cloth boards.

10. A method of producing cloth boards and similar articles, comprisingadvancing a continuous corc strip of cardboard, advancing successiveindividual core pieces of cardboard of a width substantially equal tothat of the continuous strip, and securing said pieces to a face of thestrip approximately in edgewise contact, advancing a continuous sheet ofcover paper and folding and adhesively securing the cover sheet aboutthe combined core materials to substantially enclose the same.

11. A method of producing cloth boards and similar articles comprisingadvancing a continuous corestrip of cardboard, ad vancmg successiveindividual core pieces of cardboard of a width substantially equal tothat of the continuous strip, and securing said pieces to a face of thestrip approximately in edgcwise contact, advancing a continuous sheet ofcover paper and foldingand adhesively securing I the cover sheet about.the combined core materials to substantially' enclose the same, andsevering the combined materials at regular intervals to produce theindividual cloth boards or similar articles.

12. A method of producing cloth boards and similar articles, comprisingadvancing a continuous core strip of cardboard, the fibres of which areprincipally longitudinally arranged, advancing successive individualcore pieces of cardboard of a width substantially equal to that of thestrip and applying the individual pieces adhesively to a face of thestrip in approximately edgewise contact and with .the individual piecesarranged so that their fibres are arranged principally transversely ofthe continuous strip, advancing a continuous sheet of cover paper andfolding and adhesively securing the cover strip about the combined corematerials to isubsiantially enclose them.

13. A method of producing cloth boards and similar articles, comprisingadvancing a continuous core strip of cardboard, the' fibres of which areprincipally longitudinal- 1y arranged, advancing successive individualcore pieces of cardboard of a width substantiallyequal to that of thestrip and applying the individual pieces adhesively to a face of thestrip in approximately edgewise contact and with the individual piecesarranged so that their fibres are arranged principally transversely ofthe continuous strip, advancing a continuous sheet of cover paper andfolding and adbesively securing the cover strip about the combined corematerials to substantially enclose them. and then severing the compositeassembly transversely at regular intervals to produce the individualarticles.

14. A method of producing a composite core structure, comprisingadvancing a continuous strip of cardboard core material, advancingsuccessive pieces of cardboard and aflixing them in approximatelyedgewise contact upon the strip to form a partial continuous coreassembly,producing another continuous partial core assembly in asubstantially similar manner, and bringing and adhcsively securing thetwo partial assemblies together in facial contact.

15. A method of producing cloth-bohrds or similar articles, comprisingadvancing a. continuous strip of cardboard core material, advancingsuccessive pieces of cardboard and atiixing them in approximately edgewise contact upon the strip to form a partial continuous core assembly,producing another continuous partial core assembly in a substantiallysimilar manner, bringing and adhcsively securing the two partialassemblies together in facial contact, advancing a continuous strip ofcover paper, folding and adhesively securing the cover strip about thecombined core materials to substantially enclose the same, and severingthe complete assembly so produced transversely at regular intervals toproduce the individual articles. l

.16.'A method of producing composite of such material in 19. A method,of producin structures consisting of multiple layers of sheet materialsuch-as cardboard, comprising advancing a continuous web of" suchmatcrial, advancing another continuous websive separate pieces of suchmaterial in parallel relation to the continuous web, and applying andsecuring the separate pieces to the continuous web with their endsabutting to form a continuous core structure.

- 18. A method of producing composite structures consisting of multiplelayers of sheet material such as cardboard, comprising advancing acontinuous web of such material, advancing successive separate piecesarallel relation to the continuous web, app ying and securing theseparate pieces to the continuous web with their ends substantiallyabutting to form a core structure, and folding and securing laterally.projecting portions of the continuous web to the opposite side of thecore structure. I

composite structures consisting of multip elayers of t a sheet materialsuch as cardboard, comprising advancing a plurality of continuous websof such material, applying successive se arate pieces of such materialand,secur1ng them to each of the continuous Webs, bringing the severalwebs with their applied pieces together andv securing them to form acontinuous composite assembly, and severing the assembly transversely atregular intervals to produce individual composite pieces.

Signed at New York city in the county of New York and State of New Yorkthis 27th day of September, A: D. 1922.

HARRY BRIDGMAN SMITH.

